Envelope-forming apparatus and method



s. M. WOODRUFF ET AL 3,438,310

ENVELOPE I April 15, 1969 -FORMING APPARATUS AND METHOD Sheet Filed Aug.27, 1965 G. M. WOODRUFF ETAL ENVELOPE-FORMING APPARATUS AND METHOD April15, 1969 Sheet Filed Aug. 27, 1965 April 15, 1969 wqjo ET AL 3,438,310

ENVELOPE-FORMING APPARATUS AND METHOD Filed Aug. 27, 1965 G. M. WOODRUFFET L 3,438,310

ENVELOPE-FORMING APPARATUS AND METHOD April 15, 1969 G. M. WO ODRUFF3,438,310 ENVELOPE'FORMING APPARATUS AND METHOD April 15, 1969 Filed Aug27, 1965 Sheet 3 3L .3 0 QQ n I 1 I: T; Q N. E\ R Q E w Ll L Q April 15,1969 G. M. WOODRUFF E ENVELOPE-FORMING APPARATUS AND METHOD Filed Aug.27, 1965 Sheet 6 of 7 April 15, 1969 G. M. WOODRUFF ETAL 3,438,310

ENVELOPE-FORMING APPARATUS AND METHOD Filed Aug. 27, 1965 Sheet 7 of '7United States Patent US. C]. 93-63 Claims ABSTRACT OF THE DISCLOSURE Aweb of envelope stock material is continuously fed and cut into aplurality of parallel strips of interconnected irregular envelopeblanks, the blanks of adjacent strips being longitudinally offsetrelative to one another to accommodate glue flaps formed on the sides ofeach blank. The several strips are then fed through a glue flap foldingstation and thence through rephasing mechanism to bring the blanks ofadjacent strips into longitudinal alignment to enable simultaneouslateral severance of the several strips into individual envelope blanksprior to the folding thereof into individual envelope structures.Reregistration mechanism operative subsequent to rephasing of the stripsand just prior to lateral severance thereof precisely indexes each striprelative to the severing mechanism so that the severance will occurprecisely on the line of junction between successive blanks of therespective strips.

Background of the invention This invention relates generally to a methodand machine for producing or manufacturing envelopes suitable forcontaining a dry pulverulent or granular product. More particularly, theinvention relates to the manufacture from a continuous web of envelopestock of adhesively bonded envelopes each formed of an irregular shapedenvelope blank, the production of such envelopes being accomplished athigh speed, low cost, and precise registration with predetermined areasof the web of envelope stock which is preferably pre-printed withinformation and/or decoration to be contained on the respective facesand closure flap of the resultant envelopes.

This invention is concerned with the manufacture of envelopes generallyrectangular in configuration when completely sealed, which envelopesconsist of a length of envelope stock material folded back upon itselfto provide the front and rear panels or faces of the envelope, one ofsaid panels being secured at opposite sides thereof by glue or the liketo inwardly folded glue flaps formed on the sides of the other panel tothereby constitute an envelope structure sealed along three sidesthereof and having its fourth side unsealed to provide an openingthrough which the envelope may be filled with the desired product. Oneof said panels is also formed with a closure flap along the edgedefining said opening, which closure flap is adapted to be folded overand secured to the other panel after the envelope is filled with thedesired product.

In the production of envelopes of this character there are necessarily anumber of operational steps to be performed in a certain predeterminedsequence. These steps include (1) cutting the web of envelope stock intoa pattern defining the blanks for the respective envelopes or, at least,as in the apparatus herein disclosed, cutting the envelope stock into astrip consisting of a series of interconnected envelope blanks; (2)cutting the strip of interconnected blanks transversely to separate oneblank from the other; (3) applying glue or other suitable adhesive tothe inwardly folded glue flaps extending along the sides of one panelportion of each blank; and (4) folding each blank along a transversefold line to bring the sides of one panel portion into sealing contactwith the glue coated surface of the glue flaps extending along the sidesof the other envelope panel.

Each of the aforesaid functions or steps of course requires appropriatemechanism or devices disposed at the proper stage of web travel throughthe apparatus for achieving the desired results, each said mechanism ordevice requiring its own driving means operated from a suitable powersource. Conventional apparatus of this class is generally designed toproduce the envelopes in a single series, and, in installations wherethe production requirements of the user call for machine output inexcess of that capable of being achieved by such a single seriesapparatus, the production requirements can be met only by installationof additional single series machines in sufiicient numbers such as tomeet the production requirements of the user.

In the machine according to the present invention the desired higherproduction rate or output of envelopes is achieved by designing themachine to simultaneously produce envelopes in a plurality of series,the number of such series being a matter of choice and ordinarilyspecified in accordance with the production requirements of the user.The machine or apparatus of the present: invention may thus beconsidered a multi-lane machine, each lane being represented by thatportion of the machine functioning to produce a single series ofenvelopes, as opposed to con ventional apparatus or machines designed toproduce only a single series of envelopes and which thus may be referredto as a single lane machine. By employing the multi-lane concept,equipment with the desired production capacity can be produced atconsiderably less equipment cost than would be the cost of the necessarynumber of single lane machines required to achieve the same productioncapacity. This follows from the fact that an equivalent number of singlelane machines would necessarily represent duplication of many of theparts, the duplication of which would not be required in a multi-lanemachine, these being, for example, the means for driving the mechanismsor devices for performing the essential functions of the apparatus asabove set forth. Furthermore, multi-lane equipment permits considerablesaving in the cost of the envelope stock material from which theenvelopes are made because not only is the equivalent amount of stockmaterial less expensive, when purchased in a single web of relativelywide dimensions, than if purchased in a plurality of webs ofproportionately smaller width dimension but, also, employing themulti-lane concept minimizes the amount of scrap resulting from theenvelope blank cutting operation. This minimization of scrap followsfrom the fact that each roll of envelope stock material preferablyincludes a marginal portion which is trimmed off in the formation of theenvelope blank, the trimmed-off marginal portion of the web materialserving: as protection against damage to the edge of the resultant blankduring shipment and handling of the roll and also serving as a mediumupon which may be printed appropriate lines or marks to be read byphotoelectric devices associated with automatic side edge registrationand feed correction devices. In the roll of envelope stock materialadapted for a multi-lane machine, there still would be only two marginalareas of the web removed as scrap during the blankforming operation, aproper design of the envelope blank pattern not necessitating orrequiring removal of any scrap between the several envelope blanksextending across the width of the multistrip web of stock material. Amultilane machine requires considerably less floor space and also lesssupervisory personnel than would be required by an equivalent number ofsingle lane machines, thus effecting a further saving in overheadexpenses.

The machine herein disclosed represents an embodiment of the inventionadapted for concurrently producing six series of envelopes, each seriesbeing processed by a respective one of six parallel lanes provided inthe machine. A web of envelope stock material is fed to the machine froma supply roll thereof, the web being of sufficient width to enablelongitudinal severance of the web into six parallel strips of the stockmaterial, each strip representing an interconnected series of individualenvelope blanks. The web is continuously drawn from the supply roll andintroduced to a rotary die cutter which effects the severance of the webinto the aforesaid six individual strips. The several strips ofinterconnected envelope blanks are all of the same identical pattern.However, since the individual envelope blanks do not have a uniformwidth by reason of the glue flaps projecting primarily from one panelportion thereof, the pattern of cut by the rotary die cutter is such asto render adjacent strips longitudinally offset rela tive to each othera distance equivalent to one-half the length of an individual envelopeblank. By so designing the shape of the individual envelope blanks andso cutting the web with a single line of cleavage between adjacentstrips, the projecting glue flap portions of one strip will fitcomplementally in dovetail fashion between the glue flap portions of anadjacent strip to thereby avoid waste of any web material as the resultof severing one strip from another. The rotary die cutter also makesshort slits into opposite edges of each strip along the dividing linebetween successive blanks of the strip. These slits cooperate withreregistration mechanism disposed along the feed path of the strip justprior to the envelope blank cutoff means to give assurance that theeventual cutoff of the individual blanks will be achieved precisely atthe intended location on each strip marking the line of division betweensuccessive envelope blanks, the final cutoff operating to complete thelateral severance of a strip partially effected or started by theaforesaid slits made by the rotary die cutter.

After leaving the rotary die cutter the web is fed to an assembly ofseparaing rolls in which adjoining strips of the envelope stock materialare fed through diverging feed paths in order to assure the completeseverance of these strips one from another in the event that completeseverance was not achieved by the rotary die cutter. From the separatingrolls the respective strips, now completely severed from each other, aredirected so as to converge into a common feeding plane for introductioninto side (glue) flap folding mechanism which folds the flaps inwardlyin overlying relation to the envelope panel portion from which theyextend in preparation for subsequent application of adhesive for sealingthereto the other face or panel of the envelope blank. Preferably,before effecting the inward folding of the glue flaps a spot of glue isapplied at the end of the glue flap adjacent the fold line along whichthe envelope blank is subsequently folded to complete the envelopestructure, said end of the glue flap thus being located at one corner ofthe resultant envelope. The glue spot results in the bonding of the endof the glue flap with the panel portion from which it is formed upon theinward folding of the glue flap. The bonding of the glue flap with itsrespective panel portion has been found to provide a better seal and toprevent sifting of the product through the respective corners of thecompleted envelope.

Upon leaving the side flap folding mechanism the sev* eral strips, whichnow have a lateral clearance between one another of an extent equal tothe width of the side glue flaps, are directed through a rephasing meanswhich eliminates the longitudinal offset between the individual envelopeblanks of adjacent strips and brings the respective envelope blanks ofthe several strips into substantial lat eral alignment. From therephasing mechanism the severed strips proceed to a reregistration meansfor precisely registering or aligning longitudinally the strips inpreparation for the lateral severance thereof into individual envelopeblanks. The reregistering means comprises a yieldable tensioning deviceacting in cooperation with a pair of overfeed rolls and a pair ofreregistration rolls. One reregistration roll is provided with limitstuds or pins acting in cooperation with the slits cut into the sideedges of each strip by the rotary guide cutter, so as to preciselyregister each strip with the reregistraion rolls and thereby compensatefor shrinkage or stretching of the stock or any slight misalignmentlongitudinally of a strip in its passage from the rotary guide cutterthrough the various feed stages up to the reregistration means which aredisposed immediately preceding the envelope cutoff means. From thereregistration means the several strips proceed immediately to thecutoff rolls which sever each strip precisely at the intended lineseparating one envelope blank from another which line of cut connectsthe inner limits of the slits cut into each strip by the rotary diecutter as aforementioned. The cutoff rolls also operate to crease eachenvelope blank along the lateral line separating one envelope panel fromthe other so that when the envelope blank is subsequently folded thelateral fold will be made at the precise point of the envelope blankwhich divides the front and rear panel portions thereof. From the cutoffand creasing rolls the individual envelope blanks of each strip feeddirectly through glue application rolls which apply glue to the exposedsurface of the inwardly folded glue flaps. The individual envelopeblanks then proceed to a respective pair of accelerating feed rollswhich introduce the blanks into a folding mechanism which operates tofold the blank along the lateral crease line thus bringing one panelportion of the blank into contact with the adhesively coated flapsattached to the other panel portion to thus complete the envelopesstructure. The folding mechanism includes compression rolls bearing onthe adhesively secured portions or areas of the envelope to assure afirm adhesive bond while conveying the envelopes to further compressionmeans, which may be belts or the like, to maintain the compression for asuitable time to assure the setting of the adhesive or glue, whereuponthe envelopes are discharged to any suitable collector or stackingmechanism from which they may be removed periodically as desired forstorage or insertion into an associated filling equipment as may berequired.

By provision of apparatus having features operating in the manner asabove briefly described and provided with the number of separateenvelope-forming lanes as may be needed to meet the productionrequirements of the user, the desired production volume can be achievedat a considerable amount of savings over what could be the cost ofutilizing an equivalent number of single lane machines required toproduce the same volume. These savings result not only from avoidingunnecessary duplication of several of the machine parts but also fromsavings in the cost of the envelope stock material, minimization ofscrap from the envelope blank cutting operation, a reduction in thenumber of supervisory personnel required to oversee the operation of themachine and a reduction in the amount of floor space needed by theequipment. Moreover, since various adjustments for maintaining properalignment of the envelope stock within the machine, and the criticaloperation performed by the novel reregistration means and the cut-offmeans are all performed by machine parts or members common to all lanes,the resultant envelopes are produced with a uniformity which could notbe easily or even likely obtainable through the use of a plurality ofsingle lane machines.

It is therefore the object of this invention to improve upon machineryfor producing adhesively bonded envelopes adapted for containing a drygranular or pulverant product.

It is a further object of the invention to produce envelopes of theclass described at a minimum of cost.

It is a further object of the invention to produce envelopes of the typeor class described which are consistently uniform in construction.

It is a further object of this invention to produce envelopes from apreprinted web of envelope stock wherein the respective envelopeportions are in precise registration with the printed matter containedon said envelope stock.

Further objects of the invention, together with the featurescontributing thereto and the advantages accruing therefrom, will beapparent from the following description when read in conjunction withthe accompanying drawing wherein:

FIGS. 1 and 2 taken together are a view in side elevation and partlyschematic of the entire machine;

FIG. 3 is a sectional view in elevation taken along the line 33 of FIG.2 showing the side glue flap folding mechanism;

FIG. 4 is a view in side elevation taken along the line 4-4 of FIG. 2and showing the reregistration, envelope cut-01f and related mechanism.

FIG. 5 is a plan view taken along the line 5-5 of FIG. 2 andillustrating the rephasing means and as sociated mechanism;

FIG. 6 is a plan view of a section of the web of envelope stockillustrating the pattern into which it is cut by the rotary die cutterto result in several parallel strips of interconnected envelope blanks;

FIG. 7 is a sectional view taken along the line of 77 of FIG. 4 andillustrating on a larger scale the reregistration means and the envelopecut-off means;

FIG. 8 is a view similar to FIG. 7 but at a slightly later point of anoperating cycle;

FIG. 9 is an enlarged view in section taken along line 9-9 of FIG. 8;

FIG. 10 is an enlarged detail view of one of the reregistration rolls asseen from line 1010 of FIG. 9;

FIG. 11 is an enlarged detail view of the other reregistration rolltaken along line 1111 of FIG. 9;

FIG. 12 is an enlarged detail view of a portion of the reregistrationrolls as also seen in smaller scale in FIG. 8;

FIG. 13 is a schematic view of the drive train for the reregistrationrolls, cut-off rolls, glue applicator rolls, accelerating roll, foldingmechanism and related parts;

FIG. 14 is a perspective view of a single envelope blank illustratingits orientation in preparation for entering the side flap foldingmechanism;

FIG. 15 illustrates the envelope blank in perspective leaving the sideflap folding mechanism;

FIG. 16 is a perspective view of an envelope blank in its orientationafter proceeding to the reregistration rolls and cut-off rolls;

FIG. 17 is a perspective view of an envelope blank in the process ofbeing folded to form the front and back panels of an envelope structure;

FIG. 18 is a perspective view of a completed envelope.

Referring now to the drawings and FIG. 1 in particular, the web ofenvelope stock 10 is fed to the machine from a supply roll 11 suitablyfitted with a mandrel 12 supported at each end thereof in a splitbearing assembly 13 provided at opposite sides of a supply roll stand14, one of said split bearing assemblies being shown in FIG. 1.

The envelope stock may comprise any suitable material in web form andcapable of providing the necessary strength and protective barrierqualities required by the nature of the product to be therein contained.The stock material may consist of various grades of paper laminated withwax and/or polymeric materials, a foil similarly laminated with waxesand/or polymeric materials, or a paper/foil laminate which may alsoinclude coatings of wax and/ or polymeric materials, the particularchoice of stock being dictated by the nature of the product to becontained within the resultant envelopes. Preferably the stock materialshould include a laminate which may be readily printed with productidentification and/or decorative matter, and the outer surfaces of thestock material should be of a type to which filue will readily adhere soas to produce a strong adhesive bond between the envelope portionssecured together by glue or other like adhesive. In the present instancethe envelope stock material is intended for containing a powdery, dryinstant soft drink mix, and in such an application it has been foundthat stock material having preferred qualities is one comprised of a topsheet consisting of thirty-three lbs. printed bleached chemical pulps; alaminate consisting of eighteen lbs. blend of laminating waxes andpolymeric materials; a holdout consisting of six lbs. polyethylone and abacking sheet consisting of twenty-one lbs. bleached chemical pulps.

The web 11 is unwound from the supply roll 11 by being threaded around atake-off idler roll 15 suitably mounted in the supply roll stand 14whence it is drawn upward and over a tension control roll 16 by acluster of feed rolls 17 supported in the rotary die cutter unit 20 ofthe apparatus. The feed rolls 17, driven in a manner hereinafterdescribed, serve as the means for withdrawing the Web 10 from the roll11 from which feed rolls the web is passed to rotary die cutting meansfor severing the web longitudinally into individual strips compr' ed ofinterconnected envelope blanks 5, see FIG. 14.

In order to provide a precise registration of the web of envelope stockwith the rotary die cutting means, a number of automatically operatingcontrol devices are provided. One of these devices is a side edgeregister control 21 disposed near the take-off roll 15 and includingphotoelectric means adapted to scan a running line extending along onemargin of the web, said control device controlling a motor, not shown,for laterally adjusting the supply spool 11 with respect to the supplyspool stand 14 so as to continually maintain the web in lateralregistration with the rotary die cutter unit 20. Another one of saidcontrol devices is a lonitudinal or running register control 22 suitablymounted on the die cutter unit 20 and having photoelectric meansdisposed to scan printed marks located on the opposite margin of the web10 for maintaining longitudinal registration of the web with the rotarydie cutting means by exercising a control over the speed of rotation ofthe feed rolls 17 in a manner hereinafter more fully described. Thetension control roller 16 is a part of another automatic control device,said roller being hydraulically supported in a hydraulic system wherebypressure exerted on the roller by the web acts to control through thehydraulic system a brake, not shown, associated with the web supplyspool 11 so as to maintain the tension in the web 10 between the supplyspool 11 and the feed rolls 17 at a constant degree.

The web N of envelope stock material is fed from the feed rolls 17between the cutting die rolls 25, 26 whence it proceeds to an assemblyof pull-rolls 27 between which it is properly threaded and from which itpasses out of the rotary die cutter unit 20 of the apparatus in the formof sparate parallel strips 10af, see FIG. 6, in accordance with thecutting pattern achieved by the rotary die cutter rolls 25, 26. Roll 25constitutes the male die roll, and .it is mounted in bearings 28, oneshown in FIG. 1, slidefitted in the frame of the die cutter unit 20 andadjustably tensionable by means of compression springs 31 and manuallyoperable adjustment wheels 32 mounted on threaded shafts cooperatingwith said springs 31 to selectively control the bearing pressure betweenrolls 25, 26, there being one such tension control device at each end ofthe roller 25, one shown in FIG. 1.

The rotary die cutter unit 20 is powered in a manner which is shownsomewhat diagrammatically in FIG. 1 and which power train includes amain motor 35 mounted on the front wall of the unit 20 and drivingthrough chain 36 a pinion 37 adapted to drive, through gear 40 and aslip clutch, not shown, a pinion mounted on the shaft for one of saidpull rollers 27. Pinion 37 is mounted integrally with a pinion 38disposed in meshing engagement with a pinion 39 mounted integrally witha larger pinion 41, which latter pinion engages a pinion mounted on theshaft of the die cutter roll 26 for imparting rotational torque to therolls 25, 26, it being understood that the shafts upon which the diecutter rolls are mounted are provided with in-termeshing gears, notshown, which serve to provide a driving force to the upper or male dieroll 25, while maintaining the two cutting die rolls in preciseregistration at all times. The pinion 41 also meshes with a pinion 42which is disposed in meshing engagement with the input gear 43 of adifferential drive mechanism 45. The differential drive system 45 has anoutput gear 46 which meshes with a pinion, not shown, mounted on theshaft for one of the envelope web stock feed rolls 17.

The differential drive system for operating the feed rolls 17 enablesslight variation of speed or rotational velocity of the feed rolls 17relative to the rotation of the pull rolls 27 and the rotary die cutters25, 26 by means of a correction feed input to the differential mechanismunder control of the longitudinal or running register control device 22,heretofore mentioned. The correction input factor is entered into thedifferential drive mechanism 45 from a correction motor 50, undercontrol of the photoelectric scanning device 22, said motor operatingthrough belt 51 to drive a pinion 52 suitably coupled to a differentialcage means 53, the variable drive of which affects the rotational speedof the output gear 46 to in turn alter the velocity of the feed rolls 17accordingly, so as to maintain the web being pulled off from the spoolin precise running (longitudinal) register with the rotary die cuttingrolls 25, 26.

FIG. 6 illustrates the pattern by which the web 10 is severed byoperation of the rotary die cutter. As can be seen in FIG. 6, the web isout along generally longitudinally extending lines of severance 55 so asto trim off opposite edges of the web 56, 57 and leave remaining aplurality of separate strips 10af, each representing a connected seriesof individual envelope blanks. In the present instance, six separatestrips are produced by the rotary die cutter, only four thereof beingshown in FIG. 6, which is broken away in the interest of saving space,and in cludes a showing of only the four strips 1&0, 10b, ftlc and 10The trimmed-off side border 56 contains a longitudinally runningdarkened line, not shown, which is continuously scanned by photoelectricmeans associated with the web side edge register 21 to maintain the webin correct lateral registration with the rotary die cutter, and thetimmed-oif edge 57 is printed at precisely spaced in tervals with darkspots, not shown, which are scanned by the longitudinal or runningregister control device 22 to correct the feeding velocity of the web asit passes through the rotary die cutter in the manner heretoforementioned. In FIG. 6, the cutting-through of the web is shown by thefull lines 55 which define the individual strips and the full lines 58which are small, slightly arcuate incisions made in the side edges ofeach of the strips 1la-f to enable reregistra-tion of the strips in theenvelope-forming stage of the machine as will be hereinafter described.The broken lines 61 indicate the lines along which the glue flaps 62 arefolded inwardly upon the portion of the envelope bank from which theyproject during the flap-folding state of operation as hereinafterdescribed. The broken line 63 indicates the lateral fold line upon whichthe respective envelope blanks are folded, after being cut off from therespective strip, to form front and rear panels or faces of theresultant envelope, the front panel in the present instance being theportion of the blank from which the major portion of the glue flaps 62project, the dot and dash line 64 extending between the inner ends ofthe two opposed slits 58 being the line along which the strips aresubsequently severed by the cut-off means so as to separate one envelopeblank at a time from the strip in preparation for the folding operation,as will be hereinaf-ter described. It will be noted from examination ofFIG. 6, that adjacent strips 1Gaf are longitudinally offset, one fromthe other, to an extent equal to about onehalf the length of anindividual envelope blank, thus enabling the side glue flap 62 of onestrip, such as 10b for example, to lie or fit in dovetail fashionbetween the side glue flaps 62 formed on the carton blanks of adjacentstrips Ida and file. It of course will be understood that reference to acarton blank is intended to identify that portion of each stripextending between successive lines of severance as indicated by theopposed slit connecting line 64 disposed at regularly spaced incrementsalong the length of each strip. In FIG. 6, the dotted circle 65 locatedat one end of each of the glue flaps 62 is intended to identify thelocation on each flap at which spot glue mechanism operates to deposit aspot of glue as will be hereinafter more fully described.

Referring again to FIGS. 1 and 2 in particular, the web 10, having beendivided into a plurality of individual strips 10af by the rotary diecutter, in leaving the pull rolls 27 is directed to a separating rollassembly 70 suitably mounted on the envelope-forming portion of theapparatus, which portion of the apparatus is supported by a generallyinverted U-shaped framework comprised of spaced-apart vertical frames71, 72 supporting one end, respectively of horizontal frames 73, 74, theother ends of said horizontal frames 73, 74 being supported byrespective vertical frames 75, 76, see also FIGS. 3, 4 and 5. Theseparator roll assembly 70 includes an arrangement of idler rolls 77,78, 79, the rolls 78, 79 being spaced apart, each being arranged to passthe respective group of alternate strips Mia-19f in divergent paths soas to insure complete severance of the respective strips in the eventsuch complete severance was not entirely achieved by the rotary diecutter. Thus, for example, the separate strips 10a, lltlc, lite wouldrun from roll 77 around roll 78, while strips 1%, 10d, 14] would runfrom roll 77 around roll 79, the respective groups of aternate stripsbeing fed on paths of diversion planes to assure the separation betweenadjacent strips, the respective strips subsequently converging into asingle plane in preparation for the spot gluing and side foldingoperation as hereinafter more fully described.

Since the overall distance of travel of the web material from the rotarydie cutter to the eventual cut-off means is extremely critical inachieving close registration between the envelope blanks and the printedenvelope stock from which they are cut out and formed, a take-up meansis provided for making adjustments in the overall length of the feedpath, which take-up means may comprise a take-up roll 81 carried in thearms of hell crank 32, the other arms of which bell crank are connectedby a part which is threaded to receive a threaded adjusting rod 83properly seated in the framework and rotatable manually to vary thedistance between the take-up roll 81 and roll 77 to thereby alter theoverall feed path of the web strips 10a-; and thus allow for anapproximation or rough registration of the feeding material with themeans for effecting the cut-off of the web and folding of the cut-offblanks to form the actual resultant envelopes.

From the separating roll assembly 70 the several strips 10a-f convergeinto a common feeding plane by being directed to pass over a driven roll85 in preparation for passage through the side glue flap folding means.The roll 85, as can be seen best in FIG. 3, is suitably journaled in anddisposed between the side frame plates 71, 72 of the envelope formingportion of the apparatus and is driven from the main drive motor 35,mounted on the rotary die cutter unit 20, through means which includes,see FIG. 1, a bevel gear 86 driven by pinion 42 and engaging a bevelgear 87 affixed to the end of a drive shaft 88 enclosed by a housing 89and terminating in a gear box 91, see FIG. 13, through which it drives atransverse shaft 92. The other end of shaft 92 carries a bevel gear 93meshing with bevel gear 94 fast on the lower end of an upright shaft 95.Shaft 95 carries a bevel gear 96 meshing with a bevel gear 97 on one endof shaft 98, which shaft is suitably journaled in the side frame plates71, 72 and also carries the roll 85 around which runs each of theseparate web strips a-f.

Preferably, before the separate web strips proceed to the side flapfolding means there is provided means for applying a spot of glue to apredetermined area of each glue flap 62 so that when folded inwardly itwill adhere to the panel portion of the envelope blank from which theflap projects. The precise point in the glue flap in which said spot isapplied is at the leading edge thereof, as indicated by the broken linecircular spot 65, see FIG. 6, which ultimately becomes a corner area ofthe resultant envelope when the blank is folded along the fold line 63.The means for applying said glue spot comprises a glue spot assembly 100which includes a series of glue ejecting nozzles 101 supported by andcommunicating interiorly with a tubular glue conduit or manifold 102supported at each end thereof by upright plates 103. Secured to theplates are a pair of arms 104 which are pivotally joined eccentricallyto a respective gear 105, each pair of gears 105 being operativelycoupled to each other by an idler pinion 106. Gears 105 are mounted onthe cnds of shaft 107 extending substantially across the width of theassembly and journaled in brackets 110 secured to side frames 71, 72 sothat all of said gears 105 are driven in unison. On one side of theassembly one of the gears 105 is disposed in meshing engagement with adriving gear 108 mounted on shaft 98 thus driving all gears 105 in aclockwise direction, as viewed in FIGS. 13 and 2, which, due to theeccentric pivotal connection with the arms 104, causes a clockwiserotation of the spot glue assembly comprised of the nozzles 101 and sidesupport plates 103. The rotational orbit of the tips of nozzles 101 istangent to the circumference of roll 85, and the gear ratio is such thatthe velocity of the nozzle rotation is substantially equal to thevelocity of the roll 101 so that once during each rotation of the gluespot assembly the nozzles will depoist a spot of glue on an alternategroup of web strips 1051- as they pass around the roll 85. Glue issupplied to the conduit 102 through a flexible hose 109 connecting itwith a glue pot 111, see FIG. 2, which is also connected by a hose 112to a supply of air pressure to assure a proper supply of glue to thenozzles 101. In the present instance, the gear ratio is such as to causethe nozzles to execute two revolutions during the passage of oneenvelope blank past the glue spotting zone on the roller 85 due to thefact that adjacent envelope blanks 10af are longitudinally offset onefrom the other a distance equal to onehalf the length of the blank.Accordingly, in one rotation of the nozzles 101, of which there areseven in the present instance, the glue flaps of strips 10a, 10c, 10dwill be spot glued by the six right hand nozzles 101 as viewed in FIGS.3 and 13, since there will be no glue flap in position for receivingglue from the left hand nozzle 101. During the next revolution of thenozzles 101 the spot gluing will be applied to the glue flaps ofenvelope blanks in strips 10b, 10d, 10 there being no glue flap inposition for receiving glue from the right hand nozzle 101. In order toprevent application of glue to the surface of roller 85 by the endnozzles 101 in those cycles wherein there is no flap in position toreceive the glue, the surface of roller 85 is circumferentially groovedin alignment with the end nozzles 101, said groove being indicated byreference numeral 113, as best seen in FIG. 13. The application of gluespots to the glue flaps in the position indicated which becomes a cornerof the respective envelope has been found to provide the resultantenvelope with a better seal at said corner areas so as to preventsifting at said corner areas when the envelope is used to contain aproduct having fine powdered particles.

Following the spot gluing operation, the several strips 10af proceedthrough a side flap folding operation performed by means best seen inFIG. 3, the envelope blanks of each strip being oriented in the positionshown in FIG.

14. The side flap folding means includes a vertically oriented plate 121across which several strips are drawn in a vertical direction, the plateextending between and being supported by the side frames 71, 72.Suitably mounted on said plate 121 in position to engage the side flaps62 on each of the web strips 10cz-f are two series of folding plows 122,123. It should be understood that in FIG. 3, the side flap folding meansis shown without the associated strip hold-down mechanism for reasons ofclarity, the hold-down mechanism normally bearing against the centralsurface of the web strips 1011- to maintain them in flat bearingrelationship to the plate 121. The folding of the side flaps 62 isaccomplished in two stages by the respective plows 122, 123, the firstplows 122 engaging with side flaps serving to fold them upwardly intosubstantially perpendicular relationship to the remaining strip portion.The second folding stage, effected by the plows 123, complete the inwardfolding of the flaps 62 by folding them flat against the remainingportion of the web strips in which position the previously applied gluespot is able to bond its respective area 65 of the glue flap with theadjacent surface of the associated panel portion of the envelope blankconstituting a length of the respective web strip. This stage ofenvelope formation is shown in FIG. 15. Disposed beyond or above thefolding plows 123 are preferably disposed flap hold-down guides, alsonot shown for reasons of clarity, to maintain the flaps in the fullyfolded position long enough for the glue spot to set.

The several strips 10a-f are pulled through the flap folding mechanismjust described by means of a roll 125 mounted on a shaft 126 suitablyjournaled in the side frames 71, 72, one end of the shaft 126 extendingthrough the frame 71 and carrying a bevel gear 127 meshing with a bevelgear 123 carried by the vertical. drive shaft 95. Cooperating with theroll 125 are a series of individual spring biased rollers 129, see FIG.2, of which there is one for each of the strips 10a-f, or lane of themachine, each roller 129 forming a nip with the roll 125 for receiving arespective one of the strips 10af. The rollers 129 are carried inpivotally mounted arms 130 provided with a handle 131 by which means therespective rollers can be swung away from the associated roll 125whenever desired, such as for initially threading the strips through themachine, etc.

From the roll 125, and associated rollers 129, the several strips arepassed around a driven roll 135 preparatory to rephasing the severalstrips to remove the longitudinal offset between individual envelopeblanks of adjacent strips and to bring the individual envelope blanks ofall strips Ida-f into phase wherein they are in substantial horizontalalignment, the strips now having a clearance between them due to theinward folding of the side glue flaps and thus enabling such arephasing. The roll 135 is carried by a shaft 136 extending between andsuitably journaled in the frames 71, 72. One end of shaft 136 extendsthrough frame 71 and carries a bevel gear 137 meshing with a bevel view138 carried by shaft 139, which shaft is driven from shaft 95 through asuitable gear box 140.

Rephasing of the several web strips 1011- is accomplished by passing oneset of alternately disposed strips, which up to this point have been outof phase with the other remaining alternately disposed set of strips,through a feed path differing in length from that of the other set ofstrips so that when the respective strips are again brought back into acommon feeding plane they will be substantially in phase, with theindividual envelope blanks of each of the several strips in substantiallateral alignment with one another. The rephasing mechanism can best beseen by reference to FIGS. 2, 3, 4 and 5. As the several strips leavethe roll 135, the alternately disposed strips 10a, 10c, 10e are directedto bear against the bottom surface of a shoe 145, and the alternate webstrips 10b, 10d, 10] are directed into bearing engagement with theundersurface of a respective shoe 146. Each of the shoes 145, 146 aresupported by upright rods 147 secured at their upper ends, preferably bythreads, in a support bar 148 extending between and supported by themachine frame members 73, 74. The shoes 146 are maintained at a lowerlevel than shoes 145, the mounting rods 147 for the lower shoes 146being longer than those for the upper shoes 145. In this manner adjacentweb strips are caused to feed in diverging planes, the web strips b,10a, 10f following a longer feed path than that for the other Webstrips. The several strips proceed from the shoes in converging planewhich meet when the respective strips reach yieldably mounted guidemeans of which there is one for each of the strips. The yieldablymounted guide means cooperate with the reregistration means, to behereinafter described, and each comprises a pair of arcuate support arms151, see also FIG. 7, there being one pair in each lane for a respectiveweb strip, each pair supporting a series of rollers 152 arranged tosupport and guide its respective web strip over an arcuate path ofapproximately 90 as defined by the contour of the support arms 151. Eachof the support arms 151 is pivotally mounted on a pivot rod 153extending between and supported by the side frames 73, 74, and attachedto a stud 157 joining arms 151 of each pair is an expansion spring 154connected at its other end to a tension adjustment screw 155 threadedinto a transverse bar 156 extending between and supported by the sideframes 73, 74. As will be noted, springs 154 bias the guides in acounterclockwise direction around pivot rod 153, the constructionenabling the guides to yield slightly in a clockwise direction so as toenable a slight overfeed of the web strips during the reregistrationfunction next to be described, the adjusting screws 155 enabling thetension of the springs 154 to be closely regulated.

From the web strip guide means, just described, the individual webstrips, with the envelope blanks oriented as shown in FIG. 16, are fedto roll means serving to draw the strips through the rephasing mechanismjust described and to achieve a reregistration of the strips immediatelyprior to laterally severing each of the strips, as aforementioned, intoindividual envelope blanks. The desira bility of reregistration is dueto the length of feed of the web strips from the initial die cuttingoperation to the final cut-off and the possibility, which is everpresent in web material of this nature, of a slight shrinkage or stretchof the web material which can and does render the sections of each stripintended to serve as one envelope blank, having preprinted areas 159 asindicated in FIGS. 17, 18, slightly nonuniform, particularly in length,within a limited range of tolerance. The registration means as providedwill compensate for any such nonuniformity so that the final cut-off andfolding of the individual envelope blanks will be in precise registerwith the printed portions 159 of the respective web strips.

The means for achieving the reregistration function, in cooperation withthe yieldable guides 151, includes a pair of overfeed rolls 160, 161carried by shafts 162, 163, respectively, extending between and suitablyjournaled in the upper portion of vertical machine frame plates 75, 76.Rolls 161, 161) are mounted to provide a nip clearance sufficientlygreat so as to normally prevent the web strip feed. Roller 161, however,is provided with two diametrically opposed and axially extending insertstrips 164 slightly raised from the peripheral surface of the rolls sothat during roll rotation, twice during each revolution, the inserts 164will sufficiently close the nip so as to momentarily feed the stripsthrough the nip for a predetermined distance. The roll 160 having asurface 165 of rubber or the like serves as a back-up roll for the pair,and the circumference of both rolls 161], 161 is slightly greater thanthe length of two envelope blanks so that the effect of the rolls 160,161 is to give the feeding web strips 1811- a momentary overfeed of apredetermined extent.

Disposed immediately below the overfeed rolls 160, 161

are a pair of reregistration rolls 170, 171 mounted on shafts 172, 173,respectively, mounted to provide a nip which normally engages and feedsthe web strips directed therethrough, the effective circumference of theregistration rolls 170, 171 being not oversize but equal to the lengthof two envelope blanks.

The reregistration roll is preferably coated with rubber or othermaterial having a high coefiicient of friction, which material is formedwith a series of raised surfaces or ridges 174 each aligning with thecentral portion of one of the strips 1tDa-d so as to engage therespective strip over the area thereof lying between the turned-in orinwardly folded glue flaps 62. The ridges 174 constitute the effectivefeeding surface of the roll 170 and are of a circumference equal to thelength of two envelope blanks. Disposed between the ridges 174 and indiametrically opposed relation to the roll 170 are a series of insertblocks 175, see also FIGS. 9 and 12, each block being suitably securedto a milled-out section of the roll 170 by a screw 176. Each of saidinsert blocks 175, excepting those at each end of a series, carries apair of registration pins or studs 177, each stud or pin 177 aligningvertically with the slits 58 cut into each Web strip by the rotary diecutter as aforementioned. Each of the pins 177 is fitted into a bore ofthe associated insert block 175 and is secured therein by a set screw178. The outer end of each pin 177 is undercut along a line extendingdiametrically of the pin providing a limit surface 181 on the stud tipWhich extends slightly beyond the circumference of the ridges 174 ofroll 170, which tip is formed with a top surface 182 declining outwardlyfrom the section of the pin parallel to the circumference of ridge 174to the beveled outer edge 183 of the pin.

The insert blocks 175 and studs 177, mounted on what may be consideredthe male reregistration roll 170, cooperate with insert blocks 185mounted in diametrically opposed relation to what may be referred to asthe female reregistration roll 171 and being formed with recessedportions of generally pyramidal configuration for accommodating theprotruding tips of the reregistration pins 177. The insert blocks 185are mounted in axially extending grooves in the surface of roll 171 andare secured thereto by screws 186. The outer surface 187 of the insertblock 185 in its central area is flat and thus represents a chordalsegment of the roll 171. At its end areas the surface 187 is formed witha notched recess defined by converging walls 188, 189, each recessaccommodating an associated one of the reregistration pins 177 on roll170. The inserts 185 are disposed on roll 171 in position so as to meet,during rotation, with the inserts 175 on roll 170, and since the outersurface of insert 185 is fiat, the nip clearance between the respectiverolls is increased to allow free movement of the respective strips 10afduring those portions of the cycle when the respective inserts 175, 185are in opposed relation. The female reregistration roll 171 has acircumference equal to that of the ridges 174 of the associated malereregistration roll which in turn is, as aforesaid, equal to a length oftwo envelope blanks making up the web strips 1041-7". With thereregistration rolls 170, 171 being driven at the same rpm, whichprovides them with the same surface velocity as the driven roll 135,aforementioned, the segment of roll 171 extending between diametricallyopposed inserts 185 in cooperation with the raised ridge 174 of theother reregistration roll 170 will feed the web strip an extent slightlyless than the length of one envelope blank. The outer surface of theinserts 185 which align with the ridges 174, being fiat, represent achord in the otherwise circular contour of the roll so that during theperiod of rotation starting from the position in which the leading edgeof an insert 185 is tangent to its associated ridge 174 until thetrailing edge of said insert leaves the position of tangency with saidridge 174 the feeding nip of the rolls is increased or widened, thusrendering roll 171 ineffective to feed the web during this period.

It is during this period that reregistration is accomplished in thenovel manner now to be described. Referring particularly to FIG. 7, itwill be noted that an insert 164 of roll 161 reaches the position oftangency with the cooperating raised ridge 165 of the associated roll160 and is therefore feeding the web strip at a time slightly prior tothat when the leading edge of an insert 185 of roll 171 reaches tangencywith its associated ridge 174 of roll 170. The overfeed rolls 160, 161,although driven at the same r.p.m. as the reregistration rolls 170, 171,are somewhat larger in circumference than the reregistration rolls andtherefore have a greater surface velocity causing slack in the web stripwhich tends to form a loop, as at 190. This momentary overfeed of theweb strip is made possible without tearing of the strips by reason ofthe yield provided by the support arms 151 which are rocked clockwise bythe overfeed travel of the strip increasing the tension of springs 154.The inserts 164 remain in feeding engagement until shortly after theleading edge of insert 185 reaches tangency with its associated feedingsurface 174 on the reregistration roll 170 at which time the web strip,due to its natural resiliency, straightens out by slipping through theenlarged nip of the reregistration rolls resulting from the flat surface187 of the insert 185. As the reregistration pins 177 arrive at deadcenter position within their accommodating notched recesses in the edgesof the insert 185, the position shown in FIG. 8, there is sufficientclearance between the parts to permit the free movement of the webstrip, the declining surface 182 of the reregistration pins facilitatingthe overfeed movement of the web strip through the nip provided by thereregistration rolls. Before the reregistration pins 177 reach deadcenter relationship, the position of FIG. 8, the insert 164 of theoverfeed roll 161 has moved beyond effective feeding position enablingfree movement of the web strip within the nip of the overfeed rolls,whereupon the web strip is drawn in a reverse direction or backwards bythe support arms 151 under influence of the associated springs 154. Itshould be understood that the phasing of the web strip with thereregistration rolls is such that the reregistration rolls is such thatthe portion of the strip overfed between the reregistration rollsincludes the area containing the slits 58 cut into the strip by therotary die cutter 20, as aforementioned. The backward withdrawal of theslits under influence of the spring 154 continues until or to the pointwhereat an edge of the web strip formed by the slit 58 limits againstthe undercut surface 181 of the reregistration pins 177, see also FIG.12, to precisely register each envelope blank making up a Web strip withthe reregistartion rolls 170, 171. As the rolls continue to rotate, thereregistration pins 177 are in positive engagement with the slit edgesof the strips until the trailing edge of the insert block passes thepoint of tangency with the associated raised surface or ridge 174 of thereregistration roll 170, whereupon the surface of roll 171 incooperation therewith firmly grips the strip to continue its advance inprecisely registered relation thereto to the next forming stage whereinthe strip is cut off to form individual envelope blanks.

The now precisely registered web strips feed directly to a pair ofcutoff and creasing rolls 200, 201 carried by shafts 202, 203,respectively, said shafts extending between and being suitably journaledin the side frame plates 75, 76'. The roll 200 has segments of itssurface cut away to provide radial surfaces for mounting a pair ofdiametrically opposed cutting knives 205 and a pair of diametricallyopposed creasing blades 206. The surface of roll 201 which serves as abackup roll for the roll 200 is provided with diametrically opposedinserts 207 constituting anvils for the cutting knives 205 and inserts20S constituting anvils for the creasing blades 206. The rolls 200, 201are mounted with their peripheral surfaces forming a gap or nip ofsuificient clearance to allow free movement of the web striptherethrough, the cutting knives 205 and creasing blades 206- beingadjustably secured to the roll 200 so as to project slightly beyond thecircumference thereof to achieve the desired cutting or creasingfunction. The cutoff knives 205 are mounted in two sets of six each, oneset within a corresponding cutaway segment of the roll, there being oneknife in each set for each of the web strips 10'af, each knife being ofa length sufiicient to sever the associated strip along a line 64,, seeFIG. 6, connecting the slits 58 to thus completely sever the strips intoindividual envelope blanks. A single creasing blade 206 is mounted inits respective cutout segment of the roll 200', each blade operating onall of the web strips ;10af to form a fold inducing crease along line63, see FIG. 6, it being understood that in FIG. 6 the adjacent stripsare offset Whereas when passing between rolls 200, 201 they have beenrephased and precisely registered by the reregistration rolls 170, 171as above described. As will be noted from FIGS. 7, 8, cutoff of the webstrips by the knives 205 is timed to occur just prior to the time thereregistration rolls 170, 171 momentarily discontinue feeding engagementwith the web strip, the cutoff thus not interfering with the overfeedtravel of the web strip through the reregistration roll nip or thesubsequent drawback of the strip in achieving the reregistrationfunction as above described. The effective circumferences of the cutoffand creasing rolls 205, 206 are, as are the circumferences of thereregistration rolls, equivalent to the length of two envelope blanks,the center to center distance between shafts 202, 203 and shafts 172,173, respectively, being slightly less than the length of one envelopeblank as is also the distance between the centers of shafts 172, 173 andshafts 162, 163, respectively.

From the crease and cutoff roll mechanism the individual envelope blankssevered from the respective strips IGa-f of envelope stock materialproceed to side flap gluing means which includes a glue applicator roll210 and a cooperating backup roll 211, said rolls :being carried byshafts 212, 213, respectively, suitably journaled in the side frames 75,76. The glue applicator roll as can best been seen in FIG. 4 includes aseries of spaced raised surfaces of rubber or the like 214 whichregister and engage With the intermediate portion of the respectiveenvelope blanks for feeding them in cooperation with the backup roll211. Between the raised surfaces 214 are disposed glue applicator discs215, there 'being two such discs between successive raised surfaces orridges 214 and one applicator disc 215 at each end of the series ofridges 215. Said applicator discs each register in alignment with thefolded over side glue flaps of the respective envelope blanks. Eachapplicator disc 215 is formed with two diametrically opposed segments216 of enlarged radius, which enlarged radius is slightly less than thatof the raised surface or ridges 214. Disposed below the applicator discs51 are individual glue reservoirs 2117 containing glue at a level intowhich the segments 216 dip to pick up glue and transfer it to thefolded-over flaps of the respective envelope blanks. The circumferenceof the raised surfaces 214 of the applicator roll 210 is equal to thelength of two envelope blanks so that on each revolution of the roll theinward folded side glue flaps of two successive blanks will have glueapplied thereto. Glue is supplied to the reservoirs 217 by any suitablemeans such as a supply tank 218 which is preferably under pressure froman air pressure line 219, the tank having suitable connection 221 forsupplying glue to the respective reservoirs 217. Suitable means may beprovided for controlling the level of the glue in the reservoirs and theamount of glue picked up by the segments 216 of the applicator discs215.

From the glue applicator mechanism the .individual envelope blanksfeeding in parallel in each of the respective lanes of the machineproceed to accelerating roll mechanism driven at a higher surfacevelocity than the glue applicator rolls so as to space each blank fromthe succeeding one and thereby allow sufficient time for the blankfolding operation to be hereinafter described.

The feed accelerating mechanism includes a driven roll 230, best seen inFIG. 13, mounted on a shaft 231 suitably journaled in the side frames75, 76. Cooperating with the roll 230 is a series of individual rollers232 each mounted in an individual support or cradle 233 pivotallymounted and spring-biased so as to urge its respective roller intoengagement with the roll 230. The rollers 232 are spaced so as to engagea central area of the respective envelope blanks, the spacing betweenthem allowing clearance for the inwardly folded glue flap to which gluehas been applied as hereinabove described.

The accelerating roll 230 and associated rollers 232 convey the nowseparated envelope blanks of each lane to the envelope blank foldingstation whereat the leading edge of each of the envelope blanks limitsagainst a stop 235, see FIG. 2, which preferably is adjustably mountedand extends laterally across each lane to hold the respective envelopeblanks in proper position for folding along the crease line impressedinto each envelope blank by the cut-off and crease roll mechanism 200,201, aforementioned. The stop 235 is adjusted so as to maintain thecrease line on the respective envelope blanks in registration with thenip between a pair of folding rolls 240, 241, mounted on shafts 242,243, respectively, the former extending between and suitably journaledin side frame plates 75, 76. Shaft 243 is shorter and is journaled inbearings 239 pivotally supported and yieldingly urged to force roll 241against roll 240 by any suitable means such as air cylinders 244. As canbest be seen in FIG. 4, the folding rolls 200, 201 are formed withalternately spaced sections of reduced and increased diameter, thesections of reduced diameter aligning with the central portion of anenvelope blank and the sections of increased diameter aligning with theside edges of the respective envelope blanks including the inwardlyfolded side glue flaps to which glue has been applied by the glueapplicator mechanism as above described. Cooperating with the foldingrolls are a series of reciprocally driven fold plungers 245, each in theform of a blade and there being one for each of the lanes of themachine, said plungers being supported by a carrier 246 or bail slidablymounted at each end thereof on a guide rod or shaft 247 supported bybrackets 248 suitably secured to the side frame plates 75, 76. Thecarrier 246 is driven at each end thereof by means, one shown in FiG. 2,which includes links 249 pivotally connecting the carrier to rock arms251 suitably journaled in the side frame plates 75, 76. Each rock arm251 carries a slidable sleeve 252 pivotally connected eccentrically to acrank disc 253 carried by a shaft 254 extending between and journaled inthe side frame plates 75, 76. Rotation of the crank disc 252 causeshorizontal reciprocation of the carrier 246 in timed relation to thearrival of the envelope blanks at the folding station so as to engagethe lateral crease on fold inducing line formed in each envelope blankand force the blank at said crease line into the nip of the foldingrolls 240, 241. Preferably the free folding edge of each plunger is ofsubstantially the same width as an envelope blank, the free edge beingcut away near its side edges to avoid contact with the glue applied tothe inwardly folded glue flaps as aforementioned and providing the edgeof each plunger with a central portion adapted to engage the centralportion of each envelope blank between the inwardly folded glue flapsand at its side edges with narrow fingers slightly shorter than thecentral portion of the plunger for engaging the outer edge of theenvelope blank outside of the area of the glue flap to which glue hasbeen applied. The central portion of the plunger drives the central areaof the envelope blank into the gap provided by the reduced diametersections of the folding rolls 240, 241, the side fingers of each plungerdriving the folded over glue flap portion of the envelope blank up tothe nip formed by the enlarged diameter sections of the foldin g rollsthereby cooperating to form a straight fold line in each envelope blankand preventing wrinkling in the 1% fold line, particularly at the edgesdue to the double ply thickness of the edges resulting from the inwardlyfolded glue flaps.

The folding plungers 245 engage the respective envelope blanks along thetransverse fold line 63, see FIG. 6, along which line the envelopeblanks have previously been creased by the cutting and creasing rolls200, 201 as heretofore described, the precreasing of the envelope blank,while the several strips 10af of envelope blank material are preciselyregistered in the mechanism by the reregistration means heretoforedescribed, providing assurance that the folding of the envelope blankinto an envelope structure will occur at precisely the same location oneach envelope blank as it passes between the folding rolls 240, 241. Asthe envelope blanks proceed through the nip of the folding rolls, in theattitude shown in FIG. 17, the front and back panel portions of eachenvelope blank are pressed together along their side edges, in the areaof the inwardly folded glue flaps to which glue has been applied, by thesections of the folding rolls of increased diameter to thereby bond thefront and rear panel portions of the envelope blank into an envelopestructure such as illustrated in FIG. 18.

Preferably the envelopes are delivered from the folding rolls 240, 241to a compression belt assembly 255 supported on a frame extension 257and which may be comprised of opposed endless belts 256 adapted tomaintain the glued side edge portions of each blank under compressionfor a suflicient time to assure setting of the glue, whereupon theenvelope blanks may be delivered to any suitable stacking device 260,also supported by extension 257, for receiving the completed envelopesand storing same until they may be removed in groups or stacksperiodically as needed.

The reregistration means and subsequent envelope forming means abovedescribed are driven from the common power source represented by themain motor 35,

heretofore described, through means shown schematically in FIG. 13 andincluding the drive shaft 139 which runs to a gear boX 265 mounted onthe machine frame 73, see also FIG. 4, which gear box includes bevelgears 266, 267 driving a vertically disposed shaft 268. The lower end ofshaft 268 carries a bevel gear 269 meshing with a bevel gear 270 mountedon one end of the shaft 203, which shaft, as aforementioned, carries thecutting and creasing backup roll 201. The other end of shaft 203 carriesa gear 271 meshing with a gear 272 mounted on the shaft 202 which, asaforementioned, carries the cutting and creasing roll 200. Gear 271 alsomeshes with idler gear 273 disposed in meshing engagement with a gear274 mounted on the shaft 173 which, as aforementioned, carries thereregistration roll 171. The gear 274 meshes with a gear 275 mounted onthe shaft 172 which, as aforementioned, carries the reregistration roll170. Gear 274 also meshes with an idler 276, meshing with a gear 277,mounted on the shaft 163 which, as aforementioned, carries the overfeedroll 161. The shaft 163 also carries a gear 278, slightly larger thangear 277, and disposed in meshing engagement with a gear ofcorresponding size 279, mounted on shaft 162 which, as aforementioned,carries the overfeed roll 160. By the foregoing drive means the pair ofoverfeed rolls 161, pair of reregistration rolls 170, 171, and pair ofcrease and cutoff rolls 200, 201 are each positively driven with therespective rolls of each pair turning in opposite directions so as toperform their respective functions with respect to each of the severalstrips 10a-f of envelope stock material as heretofore described.

The power train for the remaining mechanism of the envelope-formingapparatus includes a chain drive which is driven from the shaft 203which, as best seen in FIG. 13, carries a drive sprocket 281 aroundwhich is entrained an endless chain 282 extending from sprocket 281 to asprocket 283 mounted at one end of the shaft 212 which, asaforementioned, carries the glue applicator roll 210. The other end ofthe shaft 212 carries a gear 284 meshing with a gear 285, carried by theshaft 213 which, as aforementioned, supports and drives the glueapplicator backup roll 211. Chain 282 extends thence to a sprocket 286mounted on one end of shaft 231 which, as aforementioned, carries theaccelerating roll 230. It will be noted that the diameter of sprocket286 is somewhat less than that of the roll 230, which renders thesurface velocity of the roll 230 somewhat greater than that of the glueapplicator rolls 210, 211. At the other end of shaft 231 is mounted agear 287 and a sprocket 288, the latter of which may be employed fordriving the compression belt assembly 255. The gear 287 meshes with anidler gear 291, which engages 'a gear 292 mounted on one end of theshaft 242, which, as aforementioned, carries the envelope-folding roll240. Shaft 242 also carries a gear 293 meshing with a gear 294 mountedon the shaft 243 which, as aforementioned, carries the envelope-foldingcompression roll 241.

The chain 282 extends from sprocket 286 around an idler sprocket 295 andthence to a sprocket 296 mounted on a short stub shaft 297 which alsocarries a gear 298 meshing with a gear 301 mounted on one end of theshaft 254 which extends across the width of the machine and is suitablyjournaled in the side frames 75, 76. The shaft 254, as aforementioned,carries the crank discs 253, one shown in FIG. 13, which drive theenvelope fold plungers 245. The chain 282 continues from the sprocket296 around an idler sprocket 303 and thence around another idlersprocket 304, thence returning to the drive sprocket 281 to complete theendless chain circuit, it being understood that the direction of chaintravel between the respective sprockets is as shown by the arrow in FIG.13 and reverse to the order in which the respective sprockets weredescribed hereinabove.

From the foregoing, it will be apparent that the machine operates toproduce envelopes simultaneously in a plurality of parallel lanes, eachlane processing a strip of envelope stock material being continually fedtherethrough and cut from a single web of said stock material which maybe preprinted with information and/or decoration so located as to appearon the appropriate panel portions or flaps of the resultant envelopes.In so doing, the envelopes are formed at a high production rate in amanner which minimizes the amount of resultant scrap of envelope stockmaterial, and due to the provision of means for precisely registeringthe strips of envelope stock material feeding within each of theparallel lanes, each of the resultant envelopes is formed with its panelportions registering precisely with the printing of the envelope stockmaterial, each of the resultant envelopes regardless of from which lanethey are formed being in exact uniformity with all other envelopesproduced by the apparatus.

While there has been shown and described what is considered to be apreferred embodiment of the invention, it, of course, will be understoodthat obvious changes in form or details could be made without departingfrom the spirit of the invention, and it is therefore intended that theinvention be not limited to the exact form herein 'shown and describednor to anything less than the whole of the invention herein disclosed,as hereinafter claimed.

What is claimed is:

1. In an apparatus for forming envelopes from a continuous web ofenvelope stock material marked with designations for inclusion onrespective panels of the envelopes to be formed therefrom, means forcutting said web into a continuous strip of interconnected envelopeblanks registering with said designations, said cutting means includingmeans for slitting opposed side edges of said strip along part of theline of juncture between successive blanks, means for severing saidstrip in the area thereof extending between the edge areas cut by saidslitting means, and reregistration means in the feed path of said stripand disposed immediately before said severing means for preciselyadjusting each blank of said strip relative to said severing means tocause the line of cut made by said severing means to extend along theremaining part of said line of juncture and thereby complete theseparation of each of said blanks from said strip.

2. In an apparatus for forming envelopes from a continuous web ofenvelope stock material marked with designations for inclusion onrespective panels of the envelopes to be formed therefrom, means forcutting said web into a continuous strip of interconnected envelopeblanks registering with said designations, said cutting means includingmeans for slitting opposed side edges of said strip along part of theline of juncture between successive blanks, means for severing saidstrip across the area thereof lying between the edges cut by saidslitting means, means for feeding said strip from said cutting means tosaid severing means, and reregistration means in the feed path of saidstrip and disposed immediately before said severing means for preciselyadjusting each blank of said strip relative to said severing means, saidreregistering means including members engageable with the cut edges ofsaid strip made by said slitting means and operative for locating saidstrip so that said severing means effects a line of out along theremaining part of said line of juncture to thereby complete theseparation of each blank from said strip.

3. The invention according to claim 2 including means for folding eachof the blanks separated from said strip into an envelope structurehaving said respective panels marked with said designations, and meansfor accelerating the feed of said blanks when separated from said stripinto position for engagement by said folding means.

4. The invention according to claim 3 wherein said severing means aremounted integrally with members which also mount creasing meansoperative for impressing in each envelope blank a fold-inducing creasealong the line of juncture between the respective panels of each blank.

5. In an apparatus for forming envelopes from a continuous web ofenvelope stock material, means for cutting said web into a continuousstrip of interconnected envelope blanks comprising the front and rearpanels of the resultant envelope structure, each of said blanksincluding side flaps of which a major portion extends along the opposedsides of one panel of each blank and of which a minor portion extendsalong the opposed sides of the other panel of each envelope blank, meansfor severing each of said blanks from said strip, means for folding eachsevered blank along the line of juncture between the respective envelopepanels to form an envelope structure, means for continuously feedingsaid strip from said cutting means to said folding means, means disposedin the feed path of each said strip for folding said side flaps inwardlyto overlying relation to both said panels, and means disposed in thefeed path for said strip before said flap folding means for applying aspot of adhesive to the minor portion of each flap to bond the minorportion of said flaps to the panel along which they extend when saidflaps are folded over onto said panels by said flap folding means.

6. The invention according to claim 5 including means disposed in thefeed path of said strip after said flapfolding means and before saidblank folding means for applying adhesive to said inwardly folded flapson the surface of said flaps opposite to that on which adhesive isapplied by the adhesive applying means disposed before said flap foldingmeans.

7. The invention according to claim 5 wherein the means for applying aspot of adhesive to each blank includes adhesive ejecting nozzles drivenaround an orbital path at a velocity substantially equal to that of saidstrip, said path having a point of tangency with the feeding plane ofsaid strip.

8. The invention according to claim 7 wherein the driving means for saidnozzles is synchronized with the feed of said strip to dispose saidnozzles at the point of tangency coincident with the disposition of theminor portions of said flaps at said point of tangency.

9. An apparatus of the character described for processing a continuousstrip of flexible web material fed through a feed path having asuccession of feeding stages, said strip being formed at predeterminedlocations along its sides with free edge portions extending along a linedeviating from the length axis of said strip, means for registering saidstrip relative to said feed path, said registering means including apair of registration rolls engageable with said strip to advance samealong said feed path and formed to momentarily release said strip duringeach revolution for free movement relative to said rolls, said rollsbeing formed with means positively engageable with said free edgesduring the momentary period of release, and yieldable means disposed insaid feed path before said rolls for urging said strip counter to thedirection of feed by said rolls, said yieldable means imparting areverse movement to said strip during said momentary period of releaseuntil limited by said means positively engaging the free edge portionsof said strip.

10. The invention according to claim 9 including overfeed means disposedin said feed path between said registration means and said yieldablemeans, said overfeed means momentarily accelerating the feeding velocityof said strip prior to the release of said strip by said registrationmeans and against the tension of said yieldable means to cause amomentary overfeed advance of said strip past said registration meansupon the release of said strip by said registration means.

11. The invention according to claim 10 wherein said overfeed meanscomprises a pair of rolls having a surface velocity greater than that ofthe rolls comprising said registration means, one of said overfeed rollshaving a segment of enlarged radius for momentarily during eachrevolution thereof gripping said strip in cooperation with the otheroverfeed roll to cause the momentary overfeed of said strip.

12. The invention according to claim 9 wherein one of said rollscomprising said registration means is formed with a chordal segment forcausing the momentary release of said strip for free movement relativeto said rolls.

13. The invention according to claim 12 wherein the other one of saidrolls comprising said registration means is formed with pins projectingradially beyond the periphery of said roll and disposedcircumferentially so as to intersect the feed path of said strip duringthe momentary release of said strip by said rolls and to limit thereverse movement of said strip under the influence of said yieldablemeans.

14. The invention according to claim 13 wherein the chordal segment ofsaid one roll is formed with recesses disposed to accommodate said pinswhile said pins are passing through the center line between the axi ofsaid rolls.

15. The invention according to claim 9 including means for adjusting thedegree of tension imparted to said strip by said yieldable means.

16. The invention according to claim 9 wherein said yieldable meanscomprises a series of spaced-apart rollers supported in anarcuate-shaped pivotally mounted frame, said series of rollers defininga substantially arcuate section of said feed path directing said striptowards said overfeed means, said frame being biased in a directiontending to move said strip counter to its direction of feed by saidoverfeed means.

17. In an apparatus for forming envelopes from a continuous web ofenvelope stock material marked with designations for inclusion onrespective panels of the envelopes to be formed therefrom, means forcutting said web into a plurality of continuous parallel strips ofintsreonnected envelope blanks registering with said designations, saidcutting means including means for slitting the opposed side edge of eachstrip along part of the line of juncture between successive blanks,adjacent strips being longitudinally out of phase with one another,means for severing said strips in the area thereof extending betweenopposed slits in the side edges cut by said slitting means, meansdisposed between said cutting means and said severing means for placingsaid strips in substantial phase longitudinally with one another, andreregistration means in the feed path of each said strip disposedimmediately before said severing means and cooperating with the slits inthe side edges of said strips for precisely adjusting each blank of saidstrips relative to said severing means to cause the line of cut made bysaid severing means to extend along the remaining part of each line ofjuncture and thereby complete the separation of each of said blanks fromsaid strips.

18. The invention according to claim 17 wherein each of said stripsincludes side flap projecting from a portion of each envelope blankincluded in a respective strip, a side flap of each strip when initiallycut by said cutting means being accommodated in and by the marginalrecess formed between successive side flaps in an adjacent strip.

19. The invention according to claim 17 wherein said reregistrationmeans includes a pair of rolls common to all of said strips.

20. The invention according to claim 17 wherein the severance of saidstrips into individual envelope blanks includes a pair of cut-off rollscommon to all of said strips.

21. The invention according to claim 20 wherein the pair of rollscomprising said severing means includes members for impressing afold-inducing crease in each of the envelope blanks severed from all ofsaid strips.

22. The invention according to claim 17 including means for acceleratingthe feed of the envelope blanks severed from said strips into positionfor folding thereof into envelope structures, said accelerating meansincluding a roll common to the blanks severed from all of said strips.

23. The invention according to claim 22 including means for folding thesevered blanks accelerated into folding position, said folding meansincluding plungers engaging each blank and carried by a reciprocatingmember common to the blanks severed from all of said strips.

24. The invention according to claim 23 wherein said folding meansincludes a pair of folding rolls common to the envelope blanks severedfrom all of said strips.

25. The method of forming envelopes from a continuous web of envelopestock material marked with designations for inclusion in respectivepanels of the envelopes to be formed therefrom, said method comprisingthe steps of, cutting said web into a continuou strip of interconnectedenvelope blanks registering with said designations, said cuttingincluding slitting of both side edges of said strip along part of theline of juncture between successive blanks, severing said strip acrossthe area thereof extending between the side edge areas slit during thecutting of said web into a continuous strip, and reregistering saidstrip relative to its feed path for precisely adjusting each blank ofsaid strip for the severing thereof to cause the severing thereof toextend along the remaining part of said line of juncture and therebycomplete the separation of each of said blanks from said strip.

26. The invention according to claim 25 wherein the reregistering ofsaid strip is accomplished by imparting a momentary overfeed to saidstrip.

27. The invention according to claim 26 wherein the reregistering ofsaid strip includes the step of momentarily reversing the direction offeed of said strip subsequent to the overfeed of said strip.

28. The invention according to claim 25 including the step of impressinga fold-inducing crease across each of said blanks subsequent to thereregistering of said strip.

29. The invention according to claim 28 including the step ofaccelerating the feed of each envelope blank into position for foldingsubsequent to severing same from said strip.

30. The invention according to claim 29, including the step of foldingeach envelope blank when accelerated into folding position along saidfold-inducing line impressed therein.

31. The invention according to claim 25 wherein the cutting of said webof stock material proceeds along a line of cut defining side flaps foreach of said envelope blanks projecting from the respective envelopepanels and including the steps of, folding said side flaps inwardly intooverlying relation to the respective envelope panels, and applyingadhesive at a predetermined area of each flap prior to the foldingthereof to cause said flaps to adhere to the corresponding areas of saidpanels after being folded over.

32. The invention according to claim 31 including the step of applyingadhesive to said side flaps after being folded over and on the surfaceof said flaps opposite to that on which adhesive was applied prior tothe flaps being folded over.

33. The method of forming envelopes from a continuous web of envelopestock material marked with designations to be included on the respectivepanels of the envelope to be formed therefrom, said method comprisingthe steps of, cutting said web into a plurality of continuous parallelstrips of interconnected envelope blanks registering with saiddesignations, said cut-ting including the slitting of opposed side edgesof each strip along part of the line of juncture between successiveblanks of a strip, said cutting proceeding along lines renderingadjacent strips longitudinally out of phase with one another, severingsaid strips in the area thereof between the edge areas cut during theslitting of said strips, rephasing said strips before severing same torender the blanks of all strips in substantial lateral alignment withone another, and reregistering said strips subsequent to the rephasingthereof and prior to the severing thereof by positively engaging theslits cut in the side edges of said strips for precisely adjusting eachblank of said strips so that the subsequent severing thereof extendsalong the remaining part of the line of juncture and thereby completesthe separation of each blank from said strips.

34. The invention according to claim 33 wherein the cutting of saidstrips proceeds along a line of cut to form side flaps projecting fromthe blanks of one strip and interfitting with and between side flapsprojecting from the blanks of an adjacent strip.

35. The invention according to claim 33 wherein the reregistration ofall said strips is effected simultaneously.

36. The invention according to claim 33 wherein the severance of allsaid strips is effected simultaneously.

37. The invention according to claim 33 including the step of impressinga fold-inducing crease subsequent to said reregistering simultaneouslyin all blanks comprising each of the respective strips.

38. The invention according to claim 33 including the step ofaccelerating the feed of the blanks severed from all said strips intoposition for the folding thereof into envelope structures.

39. The invention according to claim 38 including the step ofsimultaneously folding the blanks accelerated into folding position.

40. The invention according to claim 39 wherein the folding of saidblanks is accomplished by members reciprocated to engage with thefold-inducing crease impressed in said blanks.

References Cited UNITED STATES PATENTS 3,383,264 5/1968 Welch 93,-61 X2,163,035 6/1939 Grupe 226-16 X 3,283,629 11/ 1966 Huck 83-75 3,344,71910/1967 Weisshuhn 93-63 3,354,798 11/1967 Winkler 93-56 FOREIGN PATENTS588,193 12/1959 Canada 1,091,495 4/ 1955 France.

WAYNE A. MORSE, JR., Primary Examiner.

US. Cl. X.R.

